Multilayer substrate materials for application to textile fabrics

ABSTRACT

A multilayer substrate material configured to be applied to a back surface of an upholstery or mattress textile fabric and a front surface configured to contact a user of the upholstery or mattress textile fabric. The multilayer substrate material includes protector, adhesive, film and backcoat layers. The adhesive layer is applied to the protector layer and formed of a number of discrete and non-continuous regions. The film layer is applied to the adhesive layer. The number of discrete and non-continuous regions include an interface between the protector layer and the film layer such that the protector layer touches the film layer at the interface. The backcoat layer is applied to the film layer and includes a non-acrylic binder and a flame retardant material. The number of discrete and non-continuous regions form a number of non-adhesive regions therebetween configured to not resist flexing of the protector, film and backcoat layers.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.15/974,064 filed on May 8, 2018, the disclosure of which is incorporatedherein by reference in its entirety.

TECHNICAL FIELD

The present invention relates to multilayer substrate materials forapplication to textile fabrics, for instance, upholstery and mattresstextile fabrics.

BACKGROUND

Treated fabrics with chemicals have been widely utilized in severalapplications. Non-limiting examples of such applications includeapplying chemical treatments to fabrics to impart certain properties tothe fabric. One example of a property is flame retardancy. Otherproperties include water repellency, water penetration resistance,abrasion resistance, and breathability. Although these prior arttreatments and treated fabrics have been utilized, improvements aredesired. There is a need for improved treatments and treated fabricsthat have improved flame retardancy with enhanced pliability and drapeand/or a more natural surface contact.

SUMMARY

In one embodiment, a multilayer substrate material configured to beapplied to a back surface of an upholstery or mattress textile fabrichaving a thickness of 0.5 to 2.0 millimeters is disclosed. Theupholstery or mattress textile fabric has a front surface configured tocontact a user of the upholstery or mattress textile fabric. Themultilayer substrate material includes a protector layer having back andfront surfaces. The adhesive layer also has first and second surfaces.The first surface of the adhesive layer is applied to the back surfaceof the protector layer. The adhesive layer is formed of a number ofdiscrete and non-continuous regions. The multilayer substrate materialincludes a film layer having first and second surfaces. The firstsurface of the film layer is applied to the second surface of theadhesive layer. The number of discrete and non-continuous regionsinclude an interface between the back surface of the protector layer andthe first surface of the film layer such that the back surface of theprotector layer touches the first surface of the film layer at theinterface. The multilayer substrate material includes a backcoat layerhaving first and second surfaces. The first surface of the backcoatlayer is applied to the second surface of the film layer. The backcoatlayer includes a non-acrylic binder and a flame retardant material. Thenumber of discrete and non-continuous regions form a number ofnon-adhesive regions therebetween configured to not resist flexing ofthe protector layer, the film layer and the backcoat layer.

In another embodiment, a multilayer substrate material configured to beapplied to a back surface of an upholstery or mattress textile fabrichaving a thickness of 0.5 to 2.0 millimeters is disclosed. Theupholstery or mattress textile fabric has a front surface configured tocontact a user of the upholstery or mattress textile fabric. Themultilayer substrate material includes a protector layer having back andfront surfaces. The multilayer substrate includes an adhesive layerhaving first and second surfaces. The first surface of the adhesivelayer is applied to the back surface of the protector layer. Theadhesive layer is formed of a number of discrete and non-continuousregions. The multilayer substrate material includes a backcoat layerhaving first and second surfaces including a non-halogenated fireretardant polymer. The multilayer substrate material includes a filmlayer situated between the protector layer and the backcoat layer. Thefirst surface of the film layer is applied to the second surface of theadhesive layer. The backcoat layer is directly applied to the filmlayer. The number of discrete and non-continuous regions include aninterface between the back surface of the protector layer and the firstsurface of the film layer such that the back surface of the protectorlayer touches the first surface of the film layer at the interface. Thenumber of discrete and non-continuous regions form a number ofnon-adhesive regions therebetween configured to not resist flexing ofthe protector layer, the film layer and the backcoat layer.

In yet another embodiment, a method of producing a multilayer substratematerial configured to be applied to a back surface of an upholstery ormattress textile fabric having a thickness of 0.5 to 2.0 millimeters isdisclosed. The upholstery or mattress textile fabric has a front surfaceconfigured to contact a user of the upholstery or mattress textilefabric. The method includes applying a film layer to a protector layerwith a hot melt adhesive using a lamination process to form an adhesivelayer having a number of discrete and non-continuous regions includingan interface between the back surface of the protector layer and thefirst surface of film layer such that the back surface of the protectorlayer touches the first surface of the film layer at the interface. Themethod further includes applying a backcoat layer to a side of the filmlayer opposite the adhesive layer. The backcoat layer includes anon-acrylic binder and a flame retardant material. The number ofdiscrete and non-continuous regions form a number of non-adhesiveregions therebetween configured to not resist flexing of the protectorlayer, the film layer and the backcoat layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a cross-sectional view of a multilayer substrateaccording to an embodiment.

FIG. 2 depicts a cross-sectional view of a multilayer substrateaccording to another embodiment.

FIG. 3 depicts a cross-sectional view of a finished composite materialaccording to an embodiment.

FIG. 4 depicts a cross-sectional view of a finished composite materialaccording to an embodiment.

FIG. 5 depicts a perspective, fragmented view of a finished compositematerial folded for a stiffness test.

FIG. 6 is a graph showing multiple test results for each treated fabricin a first group.

FIG. 7 is a graph showing multiple test results for each treated fabricin a second group.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention that may be embodied in variousand alternative forms. The figures are not necessarily to scale; somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

Except in examples, or where otherwise expressly indicated, allnumerical quantities in this description indicating amounts of materialor conditions of reaction and/or use are to be understood as modified bythe word “about” in describing the broadest scope of the invention.Unless expressly stated to the contrary: percent, “parts of,” and ratiovalues are by weight; the term “polymer” includes “oligomer,”“copolymer,” “terpolymer,” and the like; the description of a group orclass of materials as suitable or preferred for a given purpose inconnection with the invention implies that mixtures of any two or moreof the members of the group or class are equally suitable or preferred;molecular weights provided for any polymers refers to number averagemolecular weight; description of constituents in chemical terms refersto constituents at the time of addition to any combination specified inthe description, and does not necessarily preclude chemical interactionsamong the constituents of a mixture once mixed; the first definition ofan acronym or other abbreviation applies to all subsequent uses hereinof the same abbreviation and applies mutatis mutandis to normalgrammatical variations of the initially defined abbreviation; and,unless expressly stated to the contrary, measurement of a property isdetermined by the same technique as previously or later referenced forthe same property.

It is also to be understood that this invention is not limited to thespecific embodiments and methods described below, as specific componentsand/or conditions may, of course, vary. Furthermore, the terminologyused herein is used only for the purpose of describing particularembodiments of the present invention and is not intended to be limitingin any way.

It must also be noted that, as used in the specification and theappended claims, the singular form “a,” “an,” and “the” comprise pluralreferents unless the context clearly indicates otherwise. For example,reference to a component in the singular is intended to comprise aplurality of components.

Throughout this application, where publications are referenced, thedisclosures of these publications in their entireties are herebyincorporated by reference into this application to more fully describethe state of the art to which this invention pertains.

The term “about” may be used herein to describe disclosed or claimedembodiments. The term “about” may modify a value disclosed or claimed inthe present disclosure. In such instances, “about” may signify that thevalue it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10%of the value.

Developing chemical treatments for fabrics to impart flame retardancyproperties is increasing because of the proliferation of stringentflammability specifications. Standard setting organizations in theEuropean Union (EU) and European countries have enacted stringentstandards. The International Maritime Organization (IMO), which is theorganization that ensures materials on ocean-going vessels meet safetystandards, has also given flame retardancy of fabrics heightenedscrutiny. In certain aspects, the flammability requirements of the EU,European countries and the IMO are more difficult to satisfy than thedefault United States flammability standards, which are set forth inCalifornia's Technical Bulletin 133.

While current proposals for temporary and permanent flame retardantfabrics exist, the treatment to impart permanent flame retardancy maycreate a resulting treated fabric with undesirable characteristics, andtemporary flame retardancy may be unacceptable for certain applications.As an example of temporary flame retardancy, a flame retardant salt maybe applied to a fabric substrate. However, if the flame retardant saltis water soluble, it may dissolve over several washings, and therefore,does not have the wear durability of permanent flame retardancy. Knownpermanent flame retardant treated fabrics commonly have poor hand, drapeand/or pliability. For instance, current proposals include methods inwhich a backcoating including a fire retardant material is applied to afabric material. The resulting treated fabric may have undesirablecharacteristics, such as poor hand. This is especially true of fabricmaterials that are textural and have a relatively high porosity. Currentproposals also include applying a film moisture barrier to a fabricmaterial. These applications also may produce a treated fabric with poorhand and/or other undesirable characteristics, such as insufficientflame resistance.

The term “hand” may refer to the way a fabric feels when touched. Inmany instances, permanent flame retardant treated fabrics have a greasyresidue when touched that transfers to the users' fingertips. Thisgreasiness contributes to bad hand. Good hand refers to treated fabricsthat exhibit shape retention without stiffness, and do not leave behinda greasy residue. The term “drape” may refer to the manner in which acloth falls or hangs, e.g., how easily does the fabric flow down oversomething else. The term “pliability” may refer to the degree ofconformance of a fabric to angular or curved shapes, and can be measuredin terms of flexural rigidity, bending rigidity, or bending resistance.Accordingly, there remains a need for improved treated fabric productsthat have satisfactory permanent flame retardancy with a more naturalsurface contact, hand, better drape, and/or better pliability.

In one or more embodiments, treated fabrics and methods of forming thesame and in particular multilayer substrates for application to fabricsto form finished composite materials are disclosed. The treated fabricsmay impart flame retardancy properties onto the finished compositematerials while maintaining a more natural hand and/or betterpliability. In certain embodiments, a multilayer substrate is createdoffline from the fabric treatment process. By doing so, productionefficiencies and cost reductions can be realized. The multilayersubstrates may be applied to a fabric to create a finished compositematerial, where the back surface (as defined herein) of the composite islow-friction and soft and has a pleasing hand.

The finished composite materials include a substrate. In certainembodiments, the substrate is a fabric substrate. The fabric substratemay be in the form of a sheet. The thickness of the sheet may be 0.5 to2.0 mm. The fabric substrate comes into contact with the end user of thefabric application (e.g., bedding, upholstery, drapery, etc.). Accordingto one or more embodiments, the fabric substrate is treated with amultilayer substrate or a different treatment to yield a finishedcomposite material. The fabric substrate may be made of a textilematerial, such as woven, nonwoven and knitted fabrics, and one or morecomponents made from yarn-dyed or piece-dyed upholstery woven fabrics ofnatural fibers, synthetic fibers and mixtures of natural and syntheticfibers. Suitable natural fibers include without limitation fibers ofcotton, linen, ramie, silk, wool, and the like. Suitable syntheticfibers include without limitation fibers of polyamides (nylon),polyester, polyacrylic, rayon (viscose), polypropylene, polylactic acid,and the like. In one or more embodiments, a synthetic fabric is a fabriccontaining at least 40 weight percent of synthetic polymer fibers, e.g.,nylon fibers, polyester fibers, and the like.

Suitable fabrics also include without limitation jacquards (i.e.,fabrics manufactured from a jacquard loom), and dobbys (i.e., fabricsmanufactured from a dobby loom). The fabric substrate can also be one ormore blends of any of the mentioned fabrics or components.

The fabric substrate has a front surface that is exposed to the user anda back surface that is not exposed to the user in the finishedapplication (e.g., bedding or upholstery). A backcoating or multilayersubstrate may be applied to the back surface of the face fabric beforeor after backcoating or lamination. In one or more embodiments, thefabric substrate can be treated with one or more durable finishes beforeor after application of the backcoating or multilayer substrate toimpart certain desired properties onto the fabric substrate.Non-limiting examples of such properties include oil repellency, waterrepellency, soil repellency, stain repellency, liquid repellency, stainrelease, antibacterial, antifungal, odor neutralizer, water resistance,temperature modulation via phase change material or radiant heatreflection material, and flame retardancy. Non-limiting examples of thedurable finish materials include fluorinated oil and water repellentfinishes, fluorinated oil repellent finishes, fluorinated soil repellentfinishes, fluorinated liquid and stain repellent finishes, fluorinateddual-action repellent and stain release finishes, non-fluorinatedrepellent finishes, hydrophilic stain release finishes, antibacterialfinishes, antifungal finishes, odor neutralizers, and flame retardantfinishes. Non-limiting examples of phase change materials includecore-shell products in which the core is more temperature sensitive thanthe shell. For instance, the shell may be a solid material and the corematerial is a phase change material sensitive to temperature changes.The core material may solidify (and release energy) or melt (and absorbenergy) depending on the temperature.

The multilayer substrate may be applied to one of the surfaces of thefabric substrate. In one embodiment, the multilayer substrate is appliedto the back surface of the fabric substrate. The multilayer substratemay be applied to the back surface using a gravure lamination processusing a hotmelt adhesive. In certain embodiments, the hotmelt adhesiveincludes a flame retardant polymer. Hotmelt adhesives may be easilytransported in a solid state and applied in a liquid state followingheating. Non-limiting examples of hotmelt adhesives for use in one ormore embodiments include thermoplastic materials, such as, polyethylene,polypropylene, polyamide, and polyester.

In other embodiments, a reactive polyurethane (PUR) adhesive can be usedas the hotmelt adhesive. When certain PUR adhesives are melted from itssolid form, the chemical functional groups in the PUR adhesive reactwith humidity in the air to create a product that cannot be melted asecond time once the adhesive cools. Certain PUR adhesives may alsoresist separation due to reheating and/or multiple launderings. PURadhesives may react with a material surface when in the presence ofmoisture. The PUR adhesive is initially in the form of a thermoplasticmaterial, but when it is exposed to moisture in air, it becomesthermoset over a period of time (e.g., 1, 2, 3, 4, or 5 days) as thereaction takes place. During this curing period, it is important for thePUR material to remain undisturbed. If the PUR adhesive is disturbedbefore full cure, then the bond strength could be permanently reduced.The PUR adhesive is heated to a flowability temperature so that it canbe presented uniformly to a surface for adhering to a second surface.The flowability temperature may be any one of the following values orwithin a range of any two of the following values: about 90, 95, 100,105, 110, 115, 120, 125, 130, and 132° C. Once the PUR adhesive isconverted into a thermoset material, it maintains good flexibility andelasticity, which makes it ideal for flexible substrates, such asfabrics or films.

In another process, the hotmelt adhesive may be supplied in the form ofa hotmelt adhesive film or web. The film or web may be brought intocontact with the fabric substrate between upper and lower heated rollersto heat the film or web and to apply the film or web to the fabricsubstrate. Before the adhesive film or web cools, it is brought intocontact with the multilayer substrate under appropriate temperature andpressure conditions to adhere the multilayer substrate to the fabricsubstrate to form a finished composite material. The appropriatetemperature may be any one of the following values or within a range ofany two of the following values: about 90, 95, 100, 105, 110, 115, 120,125, 130, and 132° C. The appropriate pressure may be any one of thefollowing values or within a range of any two of the following values:about 1, 2, 3, 4, 5, and 6 bar nip pressure.

A lamination process can be used to apply different layers of amultilayer substrate or to apply a multilayer substrate to a fabricsubstrate. The lamination process may be a process that uses a rollerwith a shaping characteristic on the surface of the roller. For example,the roller may have a smooth shaping characteristic. In otherembodiments, the roller may have feature lines or pattern cavities andthe lamination process may be a roto-gravure lamination process. Aroto-gravure lamination process may be used to apply small quantities ofadhesive in a discrete and non-continuous format. The applied weight ofthe application of adhesive with a roto-gravure process may be any oneof the following values or within a range of any two of the followingvalues: 5, 10, 15, 20, 25, or 30 grams per meter (gsm). Regions with noadhesive are formed between the discrete regions of adhesive. Theseregions with no adhesive do not resist flexing, other than surface tosurface friction between the surfaces of adjacent layers in thoseregions.

In another embodiment, an extrusion process may be used to apply afibrous material layer to a film layer as a carrier. The fibrousmaterial may be heated so that when it is applied to the film layer, thefilm layer melts and later solidifies to attach the fibrous material tothe film. In certain instances, the film may be a thermoplastic film.

The gravure lamination process may include applying a pattern ofmicroscopic regions of adhesive to the back surface of the fabricsubstrate to bond the multilayer substrate to the fabric substrate toform a finished composite material. In one gravure lamination process,the adhesive is heated until an acceptable viscosity is reached, forexample 3,000 to 20,000 centipoise. A rotating gravure roll contacts theheated adhesive, thereby filling cavities with the adhesive. A doctorblade is applied to the surface of the gravure roll to remove excessadhesive and ensure that adhesive is only applied to the back surface inthe pattern of the cavities. The fabric or multilayer substrate ispresented to the gravure roll, after which time the fabric andmultilayer substrate pass through a nip point. The fabric substratecontacts the multilayer substrate under appropriate pressure conditionsto adhere the multilayer substrate to the fabric substrate to form afinished composite material. The appropriate pressure may be any one ofthe following values or within a range of any two of the followingvalues: about 1, 2, 3, 4, 5, and 6 bar nip pressure.

The multilayer substrate may be produced offline of the process forapplying the multilayer substrate to the textile material. Themultilayer substrate material may be stored (e.g., on a spool) beforethe application process. The offline pre-production of the multilayersubstrate decouples production of the substrate from the application andcuring process, which can take a relatively long period of time, e.g., aPUR adhesive takes 1 to 5 days to cure depending on ambient temperatureand relative humidity. Also, certain complexities may be involved in theapplication process that may negatively impact normal processingconditions, including product mix demands, labor availability, and avariety of other production delays. The decoupling of the production ofthe substrates from the application and curing process may have thebenefit of shortening lead time. Another benefit of the offlineproduction of a multilayer substrate is that the substrate productionprocess can be done at a facility separate from the treatment of thefabric substrate, and later shipped to a different facility to apply thesubstrate to the fabric substrate. Accordingly, the substrate productionprocess can be more easily kept secret at the separate facility.

FIG. 1 depicts a cross-sectional view of a multilayer substrate 10according to an embodiment. The multilayer substrate 10 includesbackcoat layer 12 having first and second surfaces 14 and 16, film layer18 having first and second surfaces 20 and 22, and layer 26 having firstand second surfaces 28 and 30. As shown in FIG. 1, layer 26 is anonwoven layer. However, in other embodiments, layer 26 may be a wovenor knit layer. Nonwoven layer 26 is applied to second surface 22 of filmlayer 18 to form an interface between second surface 22 of film layer 18and first surface 28 of nonwoven layer 26. Backcoat layer 12 is appliedto first surface 22 of film layer 18 to form an interface between firstsurface 22 of film layer 18 and second surface 16 of backcoat layer 12.A phase change material may be incorporated in backcoat layer 12. Incertain embodiments, backcoat layer 12 is optional and is not utilized.

The thickness of the film layer 18 may be any one of the followingvalues or within a range of any two of the following values: 10, 15, 20,25, or 30 microns. The applied weight of nonwoven layer 26 may be anyone of the following values or within a range of any two of thefollowing values: 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75,80, 85, 90, 95, or 100 gsm. The thickness of nonwoven layer 26 may beany one of the following values or within a range of any two of thefollowing values: 0.1, 0.5, 1.0, 1.5, or 2.0 mm. The applied weight ofbackcoat layer 12 may be any one of the following values or within arange of any two of the following values: 25, 50, 75, 100, 150, 200,300, 400, or 500 gsm. The thickness of backcoat layer 12 may be any oneof the following values or within a range of any two of the followingvalues: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1.0 mm.

In one embodiment, film layer 18 and nonwoven layer 26 are laminatedtogether using a hotmelt roto-gravure lamination process andsubsequently cured for a cure period, thereby creating adhesive layer24. The hotmelt adhesive may be a PUR adhesive. The applied weight ofthe hotmelt adhesive may be any one of the following values or within arange of any two of the following values: 5, 10, 15, 20, 25, or 30 gsm.The cure period may be about 1, 2, 3, 4, or 5 days. After the curingperiod ends, backcoat layer 12 may be coated onto first surface 22 offilm layer 12, and the backcoat layer 12 is subsequently dried andcuring in a temperature range of about 250 to 300° F. for 10 to 30seconds in which the backcoat layer 12 is within the temperature range.Maintaining the upper end of this temperature range (e.g., 280 to 300°F.) is beneficial for backcoat layers that include a cross linker. Theupper temperature range activates the cross linker to obtain a finishedcomposite material that is more wash-durable.

In one embodiment, film layer 18 may be made of a moisture barrier (MB)material. A textile coating or layer has a moisture barrier if it cansupport a considerable column of water without water penetration throughthe finished composite material. One test for water permeability andpenetration is AATCC Test Method 127-2008, available from the AATCCTechnical Manual, 2012 Edition, pp. 207-208, which is herebyincorporated in its entirety by reference. In one embodiment, thefinished composite material can withstand a hydrostatic resistance of atleast 100, 120, 140, 160, 180, or 200 cm water column pressure.“Hydrostatic pressure” as used in at least one embodiment refers to theforce distributed over an area exerted by water. In one or moreembodiments, the MB material may exhibit water vapor transmissioncharacteristics for improved breathability and end-user comfort. The MBmaterial may also contain a flame retardant polymer.

The MB material may be a thermoplastic or thermoset polymer film. Anon-limiting list of MB materials include thermoplastic polyurethane(TPU), polyester, polyamide, polypropylene, and polytetrafluoroethylene.The MB material may be a film with a relatively high melt temperature,such as a PTFE polymer film. In such instances, these films may alsoinclude an FR material. In other embodiments, the film may be made of amaterial that is inherently flame retardant.

In one embodiment, the film may be embossed or treated forauthentication or to aid in handling during subsequent processes (e.g.,cutting and sewing). Such treatments may enhance the film's aesthetics,and offer an alternative to a nonwoven treatment layer. The MB film maybe printed with a logo using an ink on each or both sides of the film.The ink may include a taggant that can be used to authenticate themanufacturer's identity and, in the absence of the taggant, to identifycounterfeit materials.

In one embodiment, backcoat layer 12 may be made from a non-acrylicpolymeric material that includes a flame retardant (FR) materialdispersed within a binder that serves to attach the FR material to asurface of the non-acrylic polymeric material. In one or moreembodiments, the FR material is configured to actively suppress theformation of flames, instead of passively resisting burning.Non-limiting examples of non-acrylic binders include polyurethane,polyvinyl chloride (PVC) and blends thereof. The FR dispersion may alsoinclude thickening agents to achieve a desired viscosity for itsapplication to a surface. The FR dispersion may also include a foamingagent that includes entrained air to improve pliability and/orflexibility of the multilayer substrate or the finished compositematerial. The FR dispersion may also contain antimicrobials forresisting the growth of bacteria and/or fungus. The FR dispersion mayalso include a colorant, pigment, or dyestuff to prevent an undesiredcondition where a layer, e.g., backcoat layer, on the other side ofnonwoven layer 26 from the fabric substrate is visible. The FRdispersion may also include a phase change material for temperaturemodulation. The FR dispersion may also include a radiant heat reflectivematerial.

In one embodiment, nonwoven layer 26 may be made of a relativelylightweight nonwoven textile material. The applied weight of thenonwoven textile material may be any one of the following values orwithin a range of any two of the following values: 20, 30, 40, 50, 60,70, 80, 90, or 100 gsm. As described above, layer 26 may be made of awoven textile material or knit textile material. The woven textilematerial may be any one of the following values or within a range of anytwo of the following values: 50, 75, 100, 125, 150, 175, or 200 gsm. Theknit textile material may be any one of the following values or within arange of any two of the following values: 50, 75, 100, 125, 150, 175, or200 gsm.

The nonwoven layer 26 may be applied to the back (non-visible) surfaceof a fabric substrate. The nonwoven layer 26 is configured to charduring combustion. The charring forms a solid material that remainsafter light gases and tar have been driven out or released from acarbonaceous material during the initial stage of combustion. The solidmaterial reduces the likelihood of complete combustion in the areaswhere the solid material forms. Therefore, those areas may not formholes or apertures so that the combustion can consume the materialslocated underneath the nonwoven layer 26, e.g., foam cushions for achair or mattress. One or more of these burn-resistant materials maypass regulatory standards, such as BS 5852 Source 5 (Crib 5) and/orCalifornia Technical Bulletin 133.

The burn-resistant material may be formed of a textile material, e.g., anonwoven textile material, woven textile material, knit textilematerial, or blend thereof, made using predominantly (e.g., about 80%,90%, 95% or 99% by weight) or solely fibers capable of leaving a charresidue that serves to prevent a flame from being presented directly tomaterials (e.g., foam) placed behind or beneath a finished compositematerial. The burn-resistant material may also be made of fibers thatresist burning. The burn-resistant material may also be made of fibersthat actively suppress flames in the presence of flames. Non-limitingexamples of burn-resistant materials include viscose FR materials,modacrylic materials, oxidated polyacrylonitrile, and polybenzimidazole(PBI) fiber materials. The burn-resistant material may be formed so thatit is relatively thin, lightweight, uniform, supple, pliable and/or hasa soft hand or touch. The burn-resistant material may include fibersconverted into a continuous web using a spunlace, spunbond, or meltblownprocess. The applied weight of the spunlace fibers may be any one of thefollowing values or within a range of any two of the following values:30, 35, 40, 45, 50, 55, or 60 gsm. The applied weight of the spunbondfibers may be any one of the following values or within a range of anytwo of the following values: 10, 15, 20, 25, or 30 gsm. The appliedweight of the meltblown fibers may be any one of the following values orwithin a range of any two of the following values: 10, 15, 20, 25, or 30gsm.

In one embodiment, film layer 18 may be made from a TPU film material,the nonwoven layer 26 may include a fire retardant nonwoven material(comprising 25, 50, 75, or 100% of nonwoven layer 26), for example, aviscose FR, spunlace fire retardant nonwoven material, which arecombined using hotmelt gravure lamination process using a PUR adhesive.This combination of materials is sufficiently heat resistant so thatthey are not damaged by the drying and curing of the subsequentapplication of backcoat layer 12, which in this and other embodiments,may be a non-acrylic polymer, for example, a non-halogenated fireretardant polymer material. In certain applications, backcoat layer 12may be omitted to reduce the cost of multilayer substrate whilemaintaining a fire retardant property through the use of fire retardantnonwoven material.

FIG. 2 depicts a cross-sectional view of a multilayer substrate 100according to another embodiment. Multilayer substrate 100 includes filmlayer 104 having first and second surfaces 106 and 108, and protectorlayer 110 having first and second surfaces 112 and 114. Film layer 104is applied to first surface 112 of protector layer 110 to form aninterface between second surface 108 of film layer 104 and first surface112 of protector layer 110. Multilayer substrate 100 may further includean optional backcoat layer 116 having first and second surfaces 118 and120. Backcoat layer 116 is applied to first surface 106 of film layer104 to form an interface between second surface 120 of backcoat layer116 and first surface 106 of film layer 104. In certain embodiments,backcoat layer 116 is optional and not utilized.

The thickness of the film layer 104 may be any one of the followingvalues or within a range of any two of the values set forth herein. Theapplied weight of protector layer 110 may be any one of the followingvalues or within a range of any two of the following values: 5, 6, 7, 8,9, 10, 11, 12, 13, 14, 15, or 20 gsm. The thickness of protector layer110 may be any one of the following values or within a range of any twoof the following values: 0.05, 0.1, 0.15, 0.2, 0.25, or 0.3 mm.

Protector layer 110 may protect film layer 104, e.g., moisture barrierfilm layer. An MB protector layer may be attached to the side of filmlayer opposite the side of the film layer facing the fabric substrate.The MB protector layer material may be a relatively lightweight textilematerial. The applied weight of the MB protector material may be any oneof the following values or within a range of any two of the followingvalues: 5, 10, 15, 20, 25, 30, 35, or 40 gsm. The MB protector materiallayer may protect the film layer, e.g., a moisture barrier film layer,from light abrasion. Also, the MB protector layer may have a lowercoefficient of friction than the film layer. In those cases, themultilayer substrate or finished composite material would be less likelyto grip a surface and would be easier to handle during subsequentprocessing (e.g., cutting and sewing). The application of an MBprotector layer may also enhance the aesthetics by avoiding a plasticlook and feel of the film layer. The MB protector material may alsoinclude FR fibers and/or materials. In one or more embodiments, the MBprotector material layer is configured to be relatively thin,lightweight, uniform, supple, pliable, soft hand or touch and/or resistspenetration of relatively hot adhesives in a liquid state. Non-limitingexamples of MB protector materials includes spunbond fibers, meltblownfibers, spunlace, polyester, inherent FR polyester, polypropylene,polyamide, viscose FR material, liner fabric, textile material, knittextile material, woven textile material and/or blends thereof. Thespunbond or meltblown materials may have an applied weight of any one ofthe following values or within a range of any two of the followingvalues: 5, 10, 15, 20, 25, 30, 35, or 40 gsm. The spunlace material mayhave an applied weight of any one of the following values or within arange of any two of the following values: 40, 45, 50, 55, or 60 gsm.

In one embodiment, film layer 104 may be made of a thermoplasticpolyurethane (TPU) film material and the protector layer 110 may be madeof a relatively lightweight textile material. The film layer 104 andprotector layer 110 can be combined using hotmelt gravure laminationprocess using a PUR adhesive. In such embodiments, the material forprotector layer 110 is selected to resist adhesive penetration when thePUR adhesive is being applied in a hot, liquid state (e.g., in thetemperature range of 90° C. to 125° C.). Resistance to liquid adhesivepenetration is beneficial to reduce or eliminate the adhesive frombinding subsequent layers of multilayer substrate 100 when it is rolledup on itself.

In certain embodiments, a hotmelt gravure lamination process is used tocombine film layer 104 and protector layer 110. The process formsadhesive layer 109 as shown in FIG. 2. The use of the hotmelt gravurelamination process helps the resulting multilayer substrate 100 achieveflexibility and a surface with soft hand and touch. In otherembodiments, backcoat layer 116 can be applied to film layer 104, andbackcoat layer 116 may be formed from a non-acrylic polymer, forexample, a non-halogenated FR latex. In one or more embodiments, thebackcoat layer material is a non-acrylic polymer material and/or blend.In those embodiments, acrylic polymer materials may not utilized becausethey are relatively more flammable than many non-acrylic polymermaterials.

FIG. 3 depicts a cross-sectional view of a finished composite material200 according to an embodiment. Finished composite material includesfabric substrate 202, film layer 204, and backcoat layer 206. Fabricsubstrate 202 includes front surface 208 and back surface 210. Filmlayer 204 includes first surface 213 and second surface 214. Backcoatlayer 206 includes first surface 216 and second surface 218. Adhesivelayer 203 is applied to back surface 210 of fabric substrate 202 tocreate an interface between back surface 210 of fabric substrate 202 andfirst surface 212 of adhesive layer 203. Film layer 204 may be formed ofa moisture barrier material. Film layer 204 may be applied to fabricsubstrate 202 using a hot adhesive gravure lamination process to produceadhesive layer 203. Backcoat layer 206 is applied to second surface 214of film layer 204 to form an interface between second surface 214 offilm layer 204 and first surface 216 of backcoat layer 206. After thecuring period for the hotmelt, backcoat layer 206 may be coated ontosecond surface 214 of film layer 204, and the backcoat layer 206 issubsequently dried and cured in a temperature range of about 250 to 300°F. for 10 to 30 seconds in which the backcoat layer 206 is within thetemperature range. Maintaining the upper end of this temperature range(e.g., 280 to 300° F.) is beneficial for backcoat layers that include across linker. The upper temperature range activates the cross linker toobtain a finished composite material that is more wash-durable. Backcoatlayer 206 may include a fire retardant material. By applying backcoatlayer 206 directly to film layer 204 instead of directly to face fabric202, one or more of the following benefits may be achieved: (a) thematerial of backcoat layer 206 may not strike through fabric substrate202, which is typically porous; and (b) the ability to see backcoatlayer 206 from the front surface 208 of fabric substrate 202 if backcoatlayer 206 partially penetrates fabric substrate 208 is minimized oravoided. In certain embodiments, fabric composite material 200 has asuperior pliability to a fabric composite material not including a filmlayer between the fabric substrate and the backcoat because the backcoatdoes not penetrate and bind to interstices within the fabric substrate.

In another embodiment, a finished composite material is made bylaminating backcoat layer 12 of substrate 10 of FIG. 1 to a fabricsubstrate using a gravure PUR adhesive lamination process. First surface14 of backcoat layer 12 is applied to the back surface of the fabricsubstrate. This application may be used with face fabrics that do notexhibit flame resistant properties, such as regular polyester materialsthat do not exhibit inherently fire retardant characteristics. Thebackcoat layer may include a fire retardant material. The fabricsubstrate may be treated with a fluorinated repellent and antimicrobialagent. This construction passes several flammability standards,including IMO Resolution A.652(16), European Union EN1021-1 and -2,British Standard (BS) 5852 Sources 0 and 1, and German DIN 4102 B2. Thisconstruction is beneficial because the fire retardant latex material ofthe backcoat layer is adjacent to the fabric substrate. The nonwovenlayer of this construction may be a char barrier material, which aids inmeeting the following flammability standards: BS 5852 Source 5 andCalifornia Technical Bulletin 133. In another embodiment, an MBprotector layer can be used instead of a nonwoven layer or char barrieras shown in FIG. 2. This substitution may be beneficial if extraresistance to hole formation is not desired. In yet another embodiment,the backcoat layer 12 is omitted when a fabric substrate made from aninherently fire retardant material is utilized.

FIG. 4 depicts a cross-sectional view of a finished composite material300 according to an embodiment. Finished composite material includesfabric substrate 302, backcoat layer 304, and film layer 306. Fabricsubstrate 302 includes front surface 308 and back surface 310. Backcoatlayer 304 includes first surface 312 and second surface 314. Film layer306 includes first surface 316 and second surface 318. Backcoat layer304 is applied to back surface 310 of fabric substrate 302 via adhesivelayer 307. Backcoat layer 304 may be coated onto back surface 310 offabric substrate 302, and the backcoat layer 304 is subsequently driedand cured in a temperature range of about 250 to 300° F. for 10 to 30seconds in which the backcoat layer 304 is within the temperature range.Maintaining the upper end of this temperature range (e.g., 280 to 300°F.) is beneficial for backcoat layers that include a cross linker. Theupper temperature range activates the cross linker to obtain a finishedcomposite material that is more wash-durable. Backcoat layer 304 mayinclude a fire retardant material. Direct application of a backcoatlayer to a fabric substrate may be beneficial when the hydrostaticresistance of the fabric substrate is less than 20 or 40 cm water columnpressure. These characteristics minimize the amount of the backcoatlayer that penetrates the interstices of the fabric substrate. Filmlayer 306 may be applied to dried and cured backcoat layer 304 using ahot adhesive (e.g., PUR adhesive) gravure lamination process. Film layer306 is applied to second surface 314 of backcoat layer 304 to form aninterface between second surface 314 of backcoat layer 304 and firstsurface 316 of film layer 306. Film layer 306 may be formed of amoisture barrier material. Optionally, a protector layer 320 can beapplied to second surface 318 of film layer 306. In one or moreembodiments, the protector layer may be made from a moisture barrier(MB) protector material. Use of the MB protector material layer may easehandling during cutting, sewing and other finishing operations byreducing the coefficient of friction of the back surface of the finishedcomposite material.

In another embodiment, film layer 104 and protector layer 110 ofmultilayer substrate 100 of FIG. 2 are laminated to a fabric substrate.In this embodiment, the fabric substrate is made of inherently fireretardant fibers (e.g., inherent fire retardant polyester). Because ofthe fire retardant characteristics of the fabric substrate, backcoatlayer 116 is omitted. Multilayer substrate 100 is laminated to thefabric substrate through a hot adhesive (e.g. PUR adhesive) gravurelamination process by applying adhesive to the back surface of thefabric substrate and applying multilayer substrate 100 by attachingfirst surface 106 of film layer 104 to the adhesive. Film layer 104 maybe made from a moisture barrier material. Film layer 104 may impartaesthetic qualities (e.g., matte finish, textile-like appearance, softhand, and/or low friction) in applications where relatively little or noadded flame retardancy is desired (e.g., outdoor fabrics).

Set forth below are examples of finished composite materials andmultilayer substrates according to one or more embodiments. As shown inthe tables below, fourteen (14) samples were prepared. Samples 1-6 wereprepared with a Sky face fabric and samples 7-12 were prepared with aCuddle face fabric. The Cuddle face fabric is relatively highly texturaland has a relatively high porosity. The Sky face fabric has lowertexturing and porosity than the Cuddle face fabric. The Cuddle and Skyface fabrics are made from 100% regular polyester (not an inherent FRpolyester). The Sky face fabric is about 1 mm thick and the Cuddle facefabric is about 2 mm thick. Samples 13 and 14 are samples of multilayersubstrates.

Sample 1 is the Sky face fabric treated with a prime coat of oil andwater repellent and silver ion antimicrobial finish applied through apad bath finish. Sample 2 is the Sky face fabric with the prime coatfinish and the application of a moisture barrier film on the backsurface of the face fabric. Sample 3 is the Sky face fabric with theprime coat finish, the moisture barrier, and a backcoat applied to themoisture barrier. Sample 4 is the Sky face fabric with the prime coatand a backcoat applied directly to the back surface of the face fabric.Sample 5 is the Sky face fabric with the prime coat, the backcoatapplied directly to the back surface of the face fabric, and themoisture barrier film applied to the backcoat. Sample 6 is treated withthe prime coat and multilayer substrate of sample 13 is then applied tothe prime coat treated sample.

Sample 7 is the Cuddle face fabric treated with a prime coat of oil andwater repellent and silver ion antimicrobial finish applied through apad bath finish. Sample 8 is the Cuddle face fabric with the prime coatfinish and the application of a moisture barrier film on the backsurface of the face fabric. Sample 9 is the Cuddle face fabric with theprime coat finish, the moisture barrier, and a backcoat applied to themoisture barrier. Sample 10 is the Cuddle face fabric with the primecoat and a backcoat applied directly to the back surface of the facefabric. Sample 11 is the Cuddle face fabric with the prime coat, thebackcoat applied directly to the back surface of the face fabric, andthe moisture barrier film applied to the backcoat. Sample 12 is treatedwith the prime coat and multilayer substrate of sample 13 is thenapplied to the prime coat treated sample.

Sample 13 is a multilayer substrate including a moisture barrier filmapplied to a viscose FR nonwoven fabric layer and a backcoat is appliedto the moisture barrier film. Sample 14 is a moisture barrier filmapplied to a viscose FR nonwoven fabric layer.

As described above, the finished composite materials and multilayersubstrates according to one or more embodiments impart flame retardancyproperties while maintaining a more natural hand and/or betterpliability. One test for pliability is ASTM 4032-08 (2012), titledStandard Test for Stiffness of Fabric by the Circular Bend Procedure,pp. 985-989, available from ASTM International, which is herebyincorporated by reference in its entirety. The test standard calls forthe folding of a fabric against itself and then being placed on aplatform with a circular aperture. A plunger is applied to the fabricsample and through the aperture while a strain gauge measures the forceapplied. The test result values are in grams-force.

As shown in FIG. 5, a face fabric sample 400 is folded onto itself sothat regions of the front surface 402 are contacting each other andregions of the back surface 404 are facing away from each other. Thedisclosed test did not account for the coefficient of friction of theexposed back surface layer. Accordingly, the values in the tables may belower if the fabric sample was folded the other way with the frontsurface regions facing away and the back surface regions facing eachother. A lower test value is indicative of a higher relative pliability,while a higher test value is indicative of a lower relative pliability.

Table 1 below shows the test values (grams-force) for multiple tests ofeach sample 1-6 and an average of the test results for each sample. FIG.6 is a graph showing the multiple test results for each treated fabricin the first group.

  1   2   3   4   5   6 Test 1  988 1482 2024 1794 2288 4858 Test 2 10861514 1860 1744 2436 4166 Test 3 1168 1382 3290 1810 2354 4198 Test 41086 1530 2322 1828 2322 4298 Test 5 1284 1548 1910 1860 2256 4562Average 1122 1491 2061 1807 2331 4416

Table 2 below shows the test values (grams-force) for multiple tests ofeach sample 7-12 and an average of the test results for each sample.FIG. 7 is a graph showing the multiple test results for each treatedfabric in the second group.

  7   8   9  10  11  12 Test 1 1482 2750 3854 3606 4380 5764 Test 2 11682668 3508 3474 4150 6060 Test 3 1234 2832 3902 3656 4314 5236 Test 41284 2882 3836 3820 4628 6010 Test 5 1398 2700 3986 3688 4792 6192Average 1313 2766 3814 3649 4453 5852

Table 3 below shows the test results (grams-force) for multiple tests ofeach sample 13 and 14 and an average of the test results for eachsample.

13 14 Test 1 410 246 Test 2 362 246 Test 3 344 278 Test 4 344 246 Test 5394 278 Average 371 259

In one or more embodiments, a suitable stiffness value may be any one ofthe following values or within a range of any two of the followingvalues: 1,400, 2,000, 2,500, 3,000, 3,500, 4,000, 4,500, 5,000, 5,500,6,000 grams-force. These stiffness values provide a suitable pliabilityfor finished composite materials having suitable flame retardanceproperties according to embodiments of the present invention.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms of the invention. Forexample, the fabric substrate, film layer, backcoat layer, protectorlayer, nonwoven layer and/or adhesive layer may include an FR material.While some embodiments disclose a fabric substrate as the substrate anda multilayer substrate being adhesively applied to the fabric substrate,other embodiments include applying a multilayer substrate to a seatcushion or mattress foam (or other form of mattress cushioning material)as the substrate without adhesive, and rather wrapping the multilayersubstrate around the seat cushion or mattress foam. Rather, the wordsused in the specification are words of description rather thanlimitation, and it is understood that various changes may be madewithout departing from the spirit and scope of the invention.Additionally, the features of various implementing embodiments may becombined to form further embodiments of the invention.

What is claimed is:
 1. A multilayer substrate material configured to beapplied to a back surface of an upholstery or mattress textile fabrichaving a thickness of 0.5 to 2.0 millimeters, the upholstery or mattresstextile fabric having a front surface configured to contact a user ofthe upholstery or mattress textile fabric, the multilayer substratematerial comprising: a protector layer having back and front surfaces;an adhesive layer having first and second surfaces, the first surface ofthe adhesive layer applied to the back surface of the protector layer,the adhesive layer formed of a number of discrete and non-continuousregions; a film layer having first and second surfaces, the firstsurface of the film layer applied to the second surface of the adhesivelayer, the number of discrete and non-continuous regions including aninterface between the back surface of the protector layer and the firstsurface of the film layer such that the back surface of the protectorlayer touches the first surface of the film layer at the interface; anda backcoat layer having first and second surfaces, the first surface ofthe backcoat layer applied to the second surface of the film layer, thebackcoat layer including a non-acrylic binder and a flame retardantmaterial, the number of discrete and non-continuous regions form anumber of non-adhesive regions therebetween configured to not resistflexing of the protector layer, the film layer and the backcoat layer.2. The multilayer substrate material of claim 1, wherein the flameretardant material is a non-halogenated flame retardant material.
 3. Themultilayer substrate material of claim 1, wherein the adhesive layerincludes a polyurethane (PUR) adhesive.
 4. The multilayer substratematerial of claim 1, wherein the protector layer, the backcoat layerand/or the film layer includes a flame retardant or burn-resistantmaterial.
 5. The multilayer substrate material of claim 1, wherein thefilm layer is formed of a thermoplastic polyurethane (TPU) material. 6.The multilayer substrate material of claim 1, wherein the backcoat layerincludes a phase change material.
 7. The multilayer substrate materialof claim 1, wherein the multilayer substrate material has a stiffness of1,400 to 6,000 grams-force according to an ASTM 4032-08 (2012) test forpliability.
 8. The multilayer substrate material of claim 1, wherein thefilm layer includes a marking to authenticate a source of the multilayersubstrate material.
 9. The multilayer substrate material of claim 1,wherein the back surface of the protector layer is facing away from thefront surface of the upholstery or mattress textile fabric, and whereina cushioning material is configured to be situated beneath or behind theback surface of the protector layer.
 10. The multilayer substratematerial of claim 9, wherein the upholstery or mattress textile fabricis the upholstery textile fabric and the cushioning material is a seatcushion.
 11. The multilayer substrate material of claim 9, wherein theupholstery or mattress textile fabric is the mattress textile fabric andthe cushioning material is a mattress foam.
 12. A multilayer substratematerial configured to be applied to a back surface of an upholstery ormattress textile fabric having a thickness of 0.5 to 2.0 millimeters,the upholstery or mattress textile fabric having a front surfaceconfigured to contact a user of the upholstery or mattress textilefabric, the multilayer substrate material comprising: a protector layerhaving back and front surfaces; an adhesive layer having first andsecond surfaces, the first surface of the adhesive layer applied to theback surface of the protector layer, the adhesive layer formed of anumber of discrete and non-continuous regions; a backcoat layer havingfirst and second surfaces including a non-halogenated fire retardantpolymer; and a film layer situated between the protector layer and thebackcoat layer, the first surface of the film layer applied to thesecond surface of the adhesive layer, the backcoat layer directlyapplied to the film layer, the number of discrete and non-continuousregions including an interface between the back surface of the protectorlayer and the first surface of the film layer such that the back surfaceof the protector layer touches the first surface of the film layer atthe interface, the number of discrete and non-continuous regions form anumber of non-adhesive regions therebetween configured to not resistflexing of the protector layer, the film layer and the backcoat layer.13. The multilayer substrate material of claim 12, wherein the backcoatlayer including a non-acrylic binder and a non-halogenated flameretardant material.
 14. The multilayer substrate material of claim 12,wherein the film layer is formed of a thermoplastic polyurethane (TPU)material.
 15. The multilayer substrate material of claim 12, wherein thefilm layer includes a marking to authenticate a source of the multilayersubstrate material.
 16. The multilayer substrate material of claim 12,wherein the backcoat layer includes a phase change material.
 17. Themultilayer substrate material of claim 12, wherein a hydrostaticresistance of the multilayer substrate material is at least 100 cm watercolumn pressure.
 18. A method of producing a multilayer substratematerial configured to be applied to a back surface of an upholstery ormattress textile fabric having a thickness of 0.5 to 2.0 millimeters,the upholstery or mattress textile fabric having a front surfaceconfigured to contact a user of the upholstery or mattress textilefabric, the method comprising: applying a film layer to a protectorlayer with a hot melt adhesive using a lamination process to form anadhesive layer having a number of discrete and non-continuous regionsincluding an interface between the back surface of the protector layerand the first surface of film layer such that the back surface of theprotector layer touches the first surface of the film layer at theinterface; and applying a backcoat layer to a side of the film layeropposite the adhesive layer, the backcoat layer including a non-acrylicbinder and a flame retardant material, the number of discrete andnon-continuous regions form a number of non-adhesive regionstherebetween configured to not resist flexing of the protector layer,the film layer and the backcoat layer.
 19. The method of claim 18,wherein the lamination process is a roto gravure lamination process. 20.The method of claim 18, wherein the hot melt adhesive is a reactivepolyurethane (PUR) adhesive.